An immersed boundary element method for level‐set based topology optimization

In this paper, we propose a new BEM for level‐set based topology optimization. In the proposed BEM, the nodal coordinates of the boundary element are replaced with the nodal level‐set function and the nodal coordinates of the Eulerian mesh that maintains the level‐set function. Because this replacement causes the nodal coordinates of the boundary element to disappear, the boundary element mesh appears to be immersed in the Eulerian mesh. Therefore, we call the proposed BEM an immersed BEM. The relationship between the nodal coordinates of the boundary element and the nodal level‐set function of the Eulerian mesh is clearly represented, and therefore, the sensitivities with respect to the nodal level‐set function are strictly derived in the immersed BEM. Furthermore, the immersed BEM completely eliminates grayscale elements that are known to cause numerical difficulties in topology optimization. By using the immersed BEM, we construct a concrete topology optimization method for solving the minimum compliance problem. We provide some numerical examples and discuss the usefulness of the constructed optimization method on the basis of the obtained results. Copyright © 2012 John Wiley & Sons, Ltd.     

A consistent grayscale‐free topology optimization method using the level‐set method and zero‐level boundary tracking mesh

This paper proposes a level‐set based topology optimization method incorporating a boundary tracking mesh generating method and nonlinear programming. Because the boundary tracking mesh is always conformed to the structural boundary, good approximation to the boundary is maintained during optimization; therefore, structural design problems are solved completely without grayscale material. Previously, we introduced the boundary tracking mesh generating method into level‐set based topology optimization and updated the design variables by solving the level‐set equation. In order to adapt our previous method to general structural optimization frameworks, the incorporation of the method with nonlinear programming is investigated in this paper. To successfully incorporate nonlinear programming, the optimization problem is regularized using a double‐well potential. Furthermore, the sensitivities with respect to the design variables are strictly derived to maintain consistency in mathematical programming. We expect the investigation to open up a new class of grayscale‐free topology optimization. The usefulness of the proposed method is demonstrated using several numerical examples targeting two‐dimensional compliant mechanism and metallic waveguide design problems. Copyright © 2014 John Wiley & Sons, Ltd.     

Adaptive moving mesh level set method for structure topology optimization

The level set method is a promising approach to provide flexibility in dealing with topological changes during structural optimization. Normally, the level set surface, which depicts a structure's topology by a level contour set of a continuous scalar function embedded in space, is interpolated on a fixed mesh. The accuracy of the boundary positions is therefore largely dependent on the mesh density, a characteristic of any Eulerian expression when using a fixed mesh. This article combines the adaptive moving mesh method with a level set structure topology optimization method. The finite element mesh automatically maintains a high nodal density around the structural boundaries of the material domain, whereas the mesh topology remains unchanged. Numerical experiments demonstrate the effect of the combination of a Lagrangian expression for a moving mesh and a Eulerian expression for capturing the moving boundaries.     

A moving superimposed finite element method for structural topology optimization

Level set methods are becoming an attractive design tool in shape and topology optimization for obtaining efficient and lighter structures. In this paper, a dynamic implicit boundary‐based moving superimposed finite element method (s‐version FEM or S‐FEM) is developed for structural topology optimization using the level set methods, in which the variational interior and exterior boundaries are represented by the zero level set. Both a global mesh and an overlaying local mesh are integrated into the moving S‐FEM analysis model. A relatively coarse fixed Eulerian mesh consisting of bilinear rectangular elements is used as a global mesh. The local mesh consisting of flexible linear triangular elements is constructed to match the dynamic implicit boundary captured from nodal values of the implicit level set function. In numerical integration using the Gauss quadrature rule, the practical difficulty due to the discontinuities is overcome by the coincidence of the global and local meshes. A double mapping technique is developed to perform the numerical integration for the global and coupling matrices of the overlapped elements with two different co‐ordinate systems. An element killing strategy is presented to reduce the total number of degrees of freedom to improve the computational efficiency. A simple constraint handling approach is proposed to perform minimum compliance design with a volume constraint. A physically meaningful and numerically efficient velocity extension method is developed to avoid the complicated PDE solving procedure. The proposed moving S‐FEM is applied to structural topology optimization using the level set methods as an effective tool for the numerical analysis of the linear elasticity topology optimization problems. For the classical elasticity problems in the literature, the present S‐FEM can achieve numerical results in good agreement with those from the theoretical solutions and/or numerical results from the standard FEM. For the minimum compliance topology optimization problems in structural optimization, the present approach significantly outperforms the well‐recognized ‘ersatz material’ approach as expected in the accuracy of the strain field, numerical stability, and representation fidelity at the expense of increased computational time. It is also shown that the present approach is able to produce structures near the theoretical optimum. It is suggested that the present S‐FEM can be a promising tool for shape and topology optimization using the level set methods. Copyright © 2005 John Wiley & Sons, Ltd.     

Three‐dimensional grayscale‐free topology optimization using a level‐set based r‐refinement method

In this paper, we propose a three‐dimensional (3D) grayscale‐free topology optimization method using a conforming mesh to the structural boundary, which is represented by the level‐set method. The conforming mesh is generated in an r‐refinement manner; that is, it is generated by moving the nodes of the Eulerian mesh that maintains the level‐set function. Although the r‐refinement approach for the conforming mesh generation has many benefits from an implementation aspect, it has been considered as a difficult task to stably generate 3D conforming meshes in the r‐refinement manner. To resolve this task, we propose a new level‐set based r‐refinement method. Its main novelty is a procedure for minimizing the number of the collapsed elements whose nodes are moved to the structural boundary in the conforming mesh; in addition, we propose a new procedure for improving the quality of the conforming mesh, which is inspired by Laplacian smoothing. Because of these novelties, the proposed r‐refinement method can generate 3D conforming meshes at a satisfactory level, and 3D grayscale‐free topology optimization is realized. The usefulness of the proposed 3D grayscale‐free topology optimization method is confirmed through several numerical examples. Copyright © 2017 John Wiley & Sons, Ltd.     

Structural shape and topology optimization using a meshless Galerkin level set method

This paper aims to propose a meshless Galerkin level set method for shape and topology optimization of continuum structures. To take advantage of the implicit free boundary representation scheme, the design boundary is represented as the zero level set of a scalar level set function, to flexibly handle complex shape fidelity and topology changes by maintaining concise and smooth interface. Compactly supported radial basis functions (CSRBFs) are used to parameterize the level set function and construct the shape functions for meshfree approximations based on a set of unstructured field nodes. The meshless Galerkin method with global weak form is used to implement the discretization of the state equations. This provides a pathway to unify the two different numerical stages in most conventional level set methods: (1) the propagation of discrete level set function on a set of Eulerian grid and (2) the approximation of discrete equations on a set of Lagrangian mesh. The original more difficult shape and topology optimization based on the level set equation is transformed into a relatively easier size optimization, to which many efficient optimization algorithms can be applied. The proposed level set method can describe the moving boundaries without remeshing for discontinuities. The motion of the free boundary is just a question of advancing the discrete level set function in time by solving the size optimization. Several benchmark examples are used to demonstrate the effectiveness of the proposed method. The numerical results show that the proposed method can simplify numerical process and avoid numerical difficulties involved in most conventional level set methods. It is straightforward to apply the proposed method to more advanced shape and topology optimization problems. Copyright © 2011 John Wiley & Sons, Ltd.     

Numerical modelling of electromechanical coupling using fictitious domain and level set methods

We present a finite element formulation for simulation of electromechanical coupling using a combination of fictitious domain and level set methods. The electric field is treated with a fixed (Eulerian‐like) mesh, whereas the structure (taken as a perfect conductor) is modelled with a conventional Lagrangian approach. The compatibility between the potential of the conductor and of the electric domain is obtained by introducing a Lagrange multiplier function, defined on the boundary of the conductor. The electromechanical forces are obtained using a variational formulation for the coupled electromechanical domain. We use a Heaviside function on the level set to remove the electric energy in the conductor domain. Results are presented for an radio frequency switch and an element of a comb drive. Copyright © 2009 John Wiley & Sons, Ltd.     

Unification of parametric and implicit methods for shape sensitivity analysis and optimization with fixed mesh

Parametric and implicit methods are traditionally thought to be two irrelevant approaches in structural shape optimization. Parametric method works as a Lagrangian approach and often uses the parametric boundary representation (B‐rep) of curves/surfaces, for example, Bezier and B‐splines in combination with the conformal mesh of a finite element model, while implicit method relies upon level‐set functions, that is, implicit functions for B‐rep, and works as an Eulerian approach in combination with the fixed mesh within the scope of extended finite element method or finite cell method. The original contribution of this work is the unification of both methods. First, a new shape optimization method is proposed by combining the features of the parametric and implicit B‐reps. Shape changes of the structural boundary are governed by parametric B‐rep on the fixed mesh to maintain the merit in computer‐aided design modeling and avoid laborious remeshing. Second, analytical shape design sensitivity is formulated for the parametric B‐rep in the framework of fixed mesh of finite cell method by means of the Hamilton–Jacobi equation. Numerical examples are solved to illustrate the unified methodology. Copyright © 2016 John Wiley & Sons, Ltd.     

A velocity field level set method for shape and topology optimization

In this paper, we propose a new implementation of the level set shape and topology optimization, the velocity field level set method. Therein, the normal velocity field is constructed with specified basis functions and velocity design variables defined on a given set of points that are independent of the finite element mesh. A general mathematical programming algorithm can be employed to find the optimal normal velocities on the basis of the sensitivity analysis. As compared with conventional level set methods, mapping the variational boundary shape optimization problem into a finite‐dimensional design space and the use of a general optimizer makes it more efficient and straightforward to handle multiple constraints and additional design variables. Moreover, the level set function is updated by the Hamilton‐Jacobi equation using the normal velocity field; thus, the inherent merits of the implicit representation is retained. Therefore, this method combines the merits of both the general mathematical programming and conventional level set methods. Integrated topology optimization of structures with embedded components of designable geometries is considered to show the capability of this method to deal with general design variables. Several numerical examples in 2D or 3D design domains illustrate the robustness and efficiency of the method using different basis functions.     

Mesh motion techniques for the ALE formulation in 3D large deformation problems

Efficient mesh motion techniques are a key issue to achieve satisfactory results in the arbitrary Lagrangian–Eulerian (ALE) finite element formulation when simulating large deformation problems such as metal‐forming. In the updated Lagrangian (UL) formulation, mesh and material movement are attached and an excessive mesh distortion usually appears. By uncoupling mesh movement from material movement, the ALE formulation can relocate the mesh to avoid distortion. To facilitate the calculation process, the ALE operator is split into two steps at each analysis time step: UL step (where deformation due to loading is calculated without convective terms) and Eulerian step (where mesh motion is applied). In this work, mesh motion is performed by new nodal relocation methods, developed for eight‐node hexahedral elements, which can move internal and boundary nodes, improving and concentrating the mesh in critical zones. After mesh motion, data is transferred from the UL mesh to the relocated mesh using an expansion of stresses in a Taylor's series. Two numerical applications are presented, comparing results of UL and ALE formulation with results found in the literature. Copyright © 2004 John Wiley & Sons, Ltd.     

An enriched finite element method and level sets for axisymmetric two‐phase flow with surface tension

A finite element method for axisymmetric two‐phase flow problems is presented. The method uses an enriched finite element formulation, in which the interface can move arbitrarily through the mesh without remeshing. The enrichment is implemented by the extended finite element method (X‐FEM) which models the discontinuity in the velocity gradient at the interface by a local partition of unity. It provides an accurate representation of the velocity field at interfaces on an Eulerian grid that is not conformal to the weak discontinuity. The interface is represented by a level set which is also used in the construction of the element enrichment. Surface tension effects are considered and the interface curvature is computed from the level set field. The method is demonstrated by several examples. Copyright © 2003 John Wiley & Sons, Ltd.     

Stress integration and mesh refinement for large deformation in geomechanics

This paper first discusses alternative stress integration schemes in numerical solutions to large‐ deformation problems in hardening materials. Three common numerical methods, i.e. the total‐Lagrangian (TL), the updated‐Lagrangian (UL) and the arbitrary Lagrangian–Eulerian (ALE) methods, are discussed. The UL and the ALE methods are further complicated with three different stress integration schemes. The objectivity of these schemes is discussed. The ALE method presented in this paper is based on the operator‐split technique where the analysis is carried out in two steps; an UL step followed by an Eulerian step. This paper also introduces a new method for mesh refinement in the ALE method. Using the known displacements at domain boundaries and material interfaces as prescribed displacements, the problem is re‐analysed by assuming linear elasticity and the deformed mesh resulting from such an analysis is then used as the new mesh in the second step of the ALE method. It is shown that this repeated elastic analysis is actually more efficient than mesh generation and it can be used for general cases regardless of problem dimension and problem topology. The relative performance of the TL, UL and ALE methods is investigated through the analyses of some classic geotechnical problems. Copyright © 2005 John Wiley & Sons, Ltd.     

Obtaining smooth mesh transitions using vertex optimization

Mesh optimization has proven to be an effective way to improve mesh quality for arbitrary Lagrangian Eulerian (ALE) simulations. To date, however, most of the focus has been on improving the geometric shape of individual elements, and these methods often do not result in smooth transitions in element size or aspect ratio across groups of elements. We present an extension to the mean ratio optimization that addresses this problem and yields smooth transitions within regions and across regions in the ALE simulation. While this method is presented in the context of ALE simulations, it is applicable to a wider set of applications that require mesh improvement, including the mesh generation process. Published in 2007 by John Wiley & Sons, Ltd.     

The fixed‐mesh ALE approach applied to solid mechanics and fluid–structure interaction problems

In this paper we propose a method to solve Solid Mechanics and fluid–structure interaction problems using always a fixed background mesh for the spatial discretization. The main feature of the method is that it properly accounts for the advection of information as the domain boundary evolves. To achieve this, we use an Arbitrary Lagrangian–Eulerian (ALE) framework, the distinctive characteristic being that at each time step results are projected onto a fixed, background mesh. For solid mechanics problems subject to large strains, the fixed‐mesh (FM)‐ALE method avoids the element stretching found in fully Lagrangian approaches. For FSI problems, FM‐ALE allows for the use of a single background mesh to solve both the fluid and the structure. Copyright © 2009 John Wiley & Sons, Ltd.     

The enriched space–time finite element method (EST) for simultaneous solution of fluid–structure interaction

The paper introduces a weighted residual‐based approach for the numerical investigation of the interaction of fluid flow and thin flexible structures. The presented method enables one to treat strongly coupled systems involving large structural motion and deformation of multiple‐flow‐immersed solid objects. The fluid flow is described by the incompressible Navier–Stokes equations. The current configuration of the thin structure of linear elastic material with non‐linear kinematics is mapped to the flow using the zero iso‐contour of an updated level set function. The formulation of fluid, structure and coupling conditions uniformly uses velocities as unknowns. The integration of the weak form is performed on a space–time finite element discretization of the domain. Interfacial constraints of the multi‐field problem are ensured by distributed Lagrange multipliers. The proposed formulation and discretization techniques lead to a monolithic algebraic system, well suited for strongly coupled fluid–structure systems. Embedding a thin structure into a flow results in non‐smooth fields for the fluid. Based on the concept of the extended finite element method, the space–time approximations of fluid pressure and velocity are properly enriched to capture weakly and strongly discontinuous solutions. This leads to the present enriched space–time (EST) method. Numerical examples of fluid–structure interaction show the eligibility of the developed numerical approach in order to describe the behavior of such coupled systems. The test cases demonstrate the application of the proposed technique to problems where mesh moving strategies often fail. Copyright © 2007 John Wiley & Sons, Ltd.     

Piecewise constant level set method for structural topology optimization

In this paper, a piecewise constant level set (PCLS) method is implemented to solve a structural shape and topology optimization problem. In the classical level set method, the geometrical boundary of the structure under optimization is represented by the zero level set of a continuous level set function, e.g. the signed distance function. Instead, in the PCLS approach the boundary is described by discontinuities of PCLS functions. The PCLS method is related to the phase‐field methods, and the topology optimization problem is defined as a minimization problem with piecewise constant constraints, without the need of solving the Hamilton–Jacobi equation. The result is not moving the boundaries during the iterative procedure. Thus, it offers some advantages in treating geometries, eliminating the reinitialization and naturally nucleating holes when needed. In the paper, the PCLS method is implemented with the additive operator splitting numerical scheme, and several numerical and procedural issues of the implementation are discussed. Examples of 2D structural topology optimization problem of minimum compliance design are presented, illustrating the effectiveness of the proposed method. Copyright © 2008 John Wiley & Sons, Ltd.     

Effects of Mesh Motion on the Stability and Convergence of ALE Based Formulations for Moving Boundary Flows

This paper investigates the effects of mesh motion on the stability of fluid-flow equations when written in an Arbitrary Lagrangian–Eulerian frame for solving moving boundary flow problems. Employing the advection-diffusion equation as a model problem we present a mathematical proof of the destabilizing effects induced by an arbitrary mesh motion on the stability and convergence of an otherwise stable scheme. We show that the satisfaction of the so-called geometric conservation laws is essential to the development of an identity that plays a crucial role in establishing stability. We explicitly show that the advection dominated case is susceptible to growth in error because of the motion of the computational grid. To retain the bound on the growth in error, the mesh motion techniques need to account for a domain based constraint that minimizes the relative mesh velocity. Analysis presented in this work can also be extended to the Navier–Stokes equations when written in an ALE frame for FSI problems.     

A semi‐implicit numerical model for storm surges

Abstract

A two‐dimensional, semi‐implicit vertically averaged circulation model using boundary‐fitted coordinates has been developed to study sea level and currents in estuarine and shelf waters. A set of coupled quasi‐linear elliptic transformation equations is used to map the physical domain to a corresponding transformed plane having a coordinate line coinciding with the body contour regardless of its shape and regular transformed mesh. The hydrodynamic equations are then solved by a semi‐implicit numerical scheme with the surface level implicitly and the velocity field explicitly in the rectangular mesh transformed grid. The numerical model was tested using two examples in which analytic solutions were available for comparison. Finally, the model was applied to predict the typhoon storm surge for Taiwan as an illustration of the model's usefulness in the practical calculations.     

Combined Eulerian–PFEM approach for analysis of polymers in fire situations

In this paper, we present a computational algorithm for solving an important practical problem, namely, the thermoplastic polymer melting under fire conditions. We propose here a technique that aims at minimizing the computational cost. This is basically achieved by using the immersed boundary‐like approach, combining the particle finite element method for the polymer with an Eulerian formulation for the ambience. The polymer and ambience domains interact over the interface boundary. The boundary is explicitly defined by the position of the Lagrangian domain (polymer) within the background Eulerian mesh (ambience). This allows to solve the energy equation for both subdomains on the Eulerian mesh with different thermal properties. Radiative transport equation is exclusively considered for the ambience, and the heat exchange at the interface is modeled by calculating the radiant heat flux and imposing it as a natural boundary condition. Copyright © 2012 John Wiley & Sons, Ltd.